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Thread: New project

  1. #1
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    New project

    Hey folks,

    I'm taking a stab at building a lugged steel single speed/fixed gear and thought I'd share my progress with you all.






    So far so good. My brazes aren't pretty but, I think they're strong. They'll look better when I'm done and have a chance to clean it up.

    It's been a lot of fun so far. As a matter of fact, if anyone is interested, I'd be willing to put in all the labor for free to build you a lugged bike of your specification (geometry, size, etc) if you want to just pay for the parts. Then again, maybe you want to see a finished bike that hasn't fallen to pieces first! =)

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    Senior Member 1jacktripper's Avatar
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    Beauty!

    PM on its way.

  3. #3
    phony collective progress x136's Avatar
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    Dang, that sounds like fun. Have you ever built a frame before? I would think that it'd be easier to start with a welded frame, but maybe not.

    What kind of tubing and lugs are you using? Paul fork end?

    I'll be interested to see the final result.

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    This is my first frame. Welded frames might be easier if you already knew how to tig weld, but I don't. Also, you don't need as much "jigging" with lugged frames as you would with welded frames. I did build a pseudo jig anyway to help with laying out some of the pieces.

    I'm using Deddacciai tubing bought from novacycles.com. The lugs are Long Shin stamped lugs. The fork is a nova cycles generic carbon fiber fork.

    I'll update the post when I make some progress.

  5. #5
    Direct Hit Not Required BlastRadius's Avatar
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    Very nice. How much will the completed frame weigh?

    edit: Just noticed novacycles.com is in Rocklin, CA. Nice and close.

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    I don't know... I'll weigh it once I finish it up. I'll weigh it pre-paint, post-paint, and with the fork and headset. And finally, with all the parts attached.

    Nova is close... their website isn't very good though. However, their service via phone has been pretty decent so far.

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    Brazed the track ends today:



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    Senior Member Chieftan's Avatar
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    How hard is it to keep everything aligned while you're brazing the pieces together? Or are the lugs snug enough that there's not enough movement to worry about? Nova Cycles is just a couple of blocks from my house...it's becoming difficult to keep from heading over there.

    Tom

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    Looking good so far, this is a fun thread to follow!

    What model is your tube miter jig? i just looked through the Grizzly catalog and couldn't find it.

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    Chieftan - Some pieces are harder to keep aligned than others. Friction does a decent job of keeping the pieces together for the most part. However, without a real jig, some of my lug angles have come out a degree or two off since the lugs do have some play in them. I use a craftsman digital angle finder to keep the rotational alignment good though, and that's probably more important. Otherwise, you can see the basic angle iron jig that I have to help with keeping the stays in place for brazing. The jig is actually something I found on instructables:

    http://www.instructables.com/id/Almo...rame-building/

    Fastev - that is a Grizzly tube notcher. Tell you the truth, I've had a lot of problems with it. One of the bolts was already stripped. The notcher shaft does not line up with the tube fixture. And the angle indicator is garbage. That being said, Grizzly has been very responsive to my complaints. They're sending me a new bolt and shaft assembly free of charge (which hopefully solve my problems.) In the meantime, I've used a flat file to align the tube fixture with the notcher and found a spare bolt to replace the stripped one. However, for the money, I can't complain that much.

    Here's the link:
    http://grizzly.com/products/G8686

    Mine is painted green and doesn't look nearly as clean and quality as the one in the pic.

    A friend of mine just got this and he seems happy with it:
    https://jointjigger.websitesource.ne...products_id=28

    It is a lot pricier though.

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    Here's a video of one of my earlier brazing attempts if you're interested:

    http://vimeo.com/2366268

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    UPS man brought my wheels today. I just threw some tubes and tires on and mocked up the the bike as is.



    Just gotta take a hair dryer to the decals.

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    Senior Member wirehead's Avatar
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    That looks seriously fun. Building my own bike frame is on the to-do-one-of-these-days list.

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    Direct Hit Not Required BlastRadius's Avatar
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    Quote Originally Posted by lemondzurich View Post
    Here's a video of one of my earlier brazing attempts if you're interested:

    http://vimeo.com/2366268
    Nice. Are you from Nebraska?

    One thing, you should get heat resistant gloves or go with no gloves. The latex would stick to your skin if it gets melted somehow.

  15. #15
    Tandem Mountain Climber
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    Quote Originally Posted by BlastRadius View Post
    Nice. Are you from Nebraska?

    One thing, you should get heat resistant gloves or go with no gloves. The latex would stick to your skin if it gets melted somehow.
    The welder/fabircator I go to for all my car related projects welds with no gloves.... However his rod is in a holder

    I don't recall if he wears them while using a torch/brazing.

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    No, I'm from Pennsylvania originally (go Penn State!) but one of my cousins is from Nebraska. Good call on the gloves. I usually remember to take them off but I get excited and forget sometimes.

    I finished the chain and seat stays today!



    Major milestone! Still have to put in a bridge in between each of the sets of stays. Thinking about spending some time doing a decorative shallow V shape with scrap pieces just for fun. I think it's aligned pretty well but there's a good chance I may have to do some minor cold setting as well. Then I have to figure out what I'm going to do about paint. Hmm.... suggestions?

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    Senior Member Chieftan's Avatar
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    Did you bolt your jig together instead of welding? I'm hoping the answer is yes, as I haven't welded in 22 years.

  18. #18
    Direct Hit Not Required BlastRadius's Avatar
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    How much do you want to spend on paint?

    Do you want wet paint or powdercoat?

    You can go cheap (rustoleum primer, color, and clearcoats), medium (powdercoat ~$125-$150), or expensive (custom painters).

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    That looks great! I'm putting together my parts list, I hope mine turns out that nice!

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    I bolted it together. And I c-clamped it to my work bench. It's not great, but it's ok.

    As for paint, I'm thinking about going cheap and just clearcoating. Can you just clearcoat on bare metal? It won't be pretty, but I kinda like the brushed steel look and this way, I can remember all the mistakes I made. =)

    I'm in the middle of making the braces now and might actually be done with it tonight!

  21. #21
    Senior Member gpelpel's Avatar
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    Amazing. You are teasing us to build our own frame. That would be a very project to do indeed.
    Yours turns out fantastic, I am looking forward to seeing the finish bike.
    Congrats on the work done so far.

  22. #22
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    I wanted to put some braces between the stays but all my scrap was tapered so I had to use two pieces, butted together to make a single symmetrical brace. Instead of doing them plain jane straight across, I decided to give them a little flair and angled them a bit. Here's the result:

    Chain stay stiffener:


    Seat stay stiffener:



    The only other thing I did today was trim off the excess head tube. Now I just need to spend a little time making some of the joints a little prettier and then it's off to the bike shop to get the head tube faced and reamed for the headset and have the seat tube reamed for my seat post.

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    thats cool man-

    im also in the phase of thinking of building a frame- possibly lugged-

    my friend has a bike jig that he built for our schools metal shop- he built a road bike with it-

    and i've been planning to use it to build a lugged track frame-

    it is pretty easy brazing together a lugged frame?

    would you happen to know of any good resources online to show specifically how to build a lugged frame?

  24. #24
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    Well, I'm not sure if I'd say it's easy. It depends on how much experience you have in a shop and working with tools and metal, etc. Brazing isn't rocket science, but it does take some experience to do well. If you do a search on youtube for brazing, you can get an idea of what it's about. My buddy posted some videos that were helpful. Search for mchimonas and they should come up. I think there were a series of 7 videos.

    Otherwise, google is your friend. Check out bob brown, henry james, nova cycle supply, richard sachs. And if you have specific questions, let me know.

  25. #25
    Direct Hit Not Required BlastRadius's Avatar
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    Plain clearcoat is probably okay but it'd be hard to tell when there's a scratch without waiting for rust to show up.

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